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English Original instructions

SERVICE MANUAL FOR HOIST - - - 003016

11.2014

Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

SUPDOC_SM_Q160100-0 PS17984 7.11.2014

SUPDOC_SM_Q16-0.ORD 7.11.2014

R&M Materials Handling, Inc. Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

Table of contents

1 2

3

4

5

6

7

UPDATE HISTORY ............................................................................................................................ 4 GENERAL INTRODUCTION .............................................................................................................. 5 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

Foreword: About this manual............................................................................................................5 Symbols used in this manual ............................................................................................................5 Safety Alert Symbols and Signal Words ...........................................................................................5 Questions and Comments ................................................................................................................6 Manual Use.......................................................................................................................................6 Service personnel .............................................................................................................................6 Terminology ......................................................................................................................................7 Standards and Directives .................................................................................................................7

3.1 3.1.1 3.2 3.3 3.4 3.4.1

Personal protective equipment (PPE) ..............................................................................................8 Fall Protection ...................................................................................................................................8 Fire Safety ........................................................................................................................................9 Main isolation switch .........................................................................................................................9 Safety during maintenance ...............................................................................................................9 Lockout - Tagout Procedure ...........................................................................................................11

4.1 4.2 4.3 4.4 4.5

Manufacturer ...................................................................................................................................12 Hoist series .....................................................................................................................................13 Hoist Identification Data ..................................................................................................................14 R&M code example (R&M: SX, Factory: Q) ...................................................................................15 Motor Identification Data .................................................................................................................16

SAFETY FIRST! ................................................................................................................................. 8

IDENTIFICATION............................................................................................................................. 12

GENERAL ABOUT MAINTENANCE ................................................................................................ 18 5.1 5.2 5.2.1 5.2.2 5.3 5.3.1

Service process ..............................................................................................................................18 Periodic inspections and actions ....................................................................................................19 Daily inspections .............................................................................................................................19 Periodic inspections and maintenance tasks .................................................................................19 Approaching Theoretical Calculated Lifetime .................................................................................21 General Overhaul ...........................................................................................................................21

6.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.2.9

Periodic inspections and maintenance tasks .................................................................................23 Lubrication ......................................................................................................................................34 General Lubrication Instructions .....................................................................................................34 Lubrication Charts (Low headroom trolley) ....................................................................................36 Lubrication Charts (Normal headroom trolley) ...............................................................................37 Lubrication Charts (Double girder trolley) .......................................................................................38 Lubrication Charts (Fixed hoist) ......................................................................................................39 Lubrication Charts (Machinery Hoist) .............................................................................................40 Lubricant volumes, hoisting gears ..................................................................................................44 Lubricant volumes, drum rim gear ..................................................................................................44 Lubricant volumes, traveling gears .................................................................................................44

7.1 7.1.1 7.1.2 7.1.3 7.1.4

Hoisting machinery .........................................................................................................................45 Hoisting machinery .........................................................................................................................45 Rope drum ......................................................................................................................................53 Rope clamps ...................................................................................................................................56 Rope guide .....................................................................................................................................58

MAINTENANCE PROGRAM ............................................................................................................ 23

MAINTENANCE INSTRUCTIONS.................................................................................................... 45

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc. Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

8 9

7.1.5 7.1.6 7.1.7 7.1.8 7.1.9 7.1.10 7.1.11 7.1.12 7.1.13 7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8 7.2.9 7.3 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.4 7.4.1 7.4.2 7.4.3 7.4.4 7.4.5

Hoisting gearbox ............................................................................................................................. 82 Hoisting motor ................................................................................................................................ 88 Hoisting brake................................................................................................................................. 93 Second brake, Frame size: SX1, SX2, SX3, SX4, SX5. ................................................................ 98 Drum Brake .................................................................................................................................. 100 Manual brake release for hoisting motor ...................................................................................... 119 Manual crank ................................................................................................................................ 122 Hoisting limit switch ...................................................................................................................... 125 Hook operated limit switch ........................................................................................................... 134 Rope reeving system .................................................................................................................... 141 Standard reevings (one rope from drum) ..................................................................................... 141 True vertical reevings (two ropes from drum)............................................................................... 145 Machinery reevings ...................................................................................................................... 148 Rope sheave maintenance ........................................................................................................... 150 Sheave support and rope anchorage support .............................................................................. 151 Wire rope ...................................................................................................................................... 152 Hook-block .................................................................................................................................... 160 Overload protection ...................................................................................................................... 175 Rope anchorage ........................................................................................................................... 180 Trolley ........................................................................................................................................... 185 Trolley ........................................................................................................................................... 185 Trolley buffers ............................................................................................................................... 187 Traveling machinery ..................................................................................................................... 188 Traveling motor ............................................................................................................................. 191 Traveling brake ............................................................................................................................. 195 Trolley wheels ............................................................................................................................... 201 Electrics ........................................................................................................................................ 210 Push-button controller .................................................................................................................. 210 Condition monitoring unit .............................................................................................................. 211 Frequency converters ................................................................................................................... 212 Cubicles and wiring ...................................................................................................................... 215 Contactors .................................................................................................................................... 215

8.1 8.2

Dismantling the Product ............................................................................................................... 216 Disposal of Waste Material ........................................................................................................... 217

DISMANTLING .............................................................................................................................. 216 APPENDIX: TIGHTENING TORQUES .......................................................................................... 218

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc. Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

1

UPDATE HISTORY

Section Whole document Whole document Whole document

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Description New layout and several product updates Updates and corrections Updates and corrections. Integrating partial GO as part of maintenance tasks. Instructions on replacing gearbox sealings in smaller drum frame sizes added.

Date 12.2011 10.2013 11.2014

Handled by KHHJII XJAASKPA XJAASKPA

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc. Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

2 2.1

GENERAL INTRODUCTION Foreword: About this manual

This manual offers guidance to enable safe and efficient service. Taking the time to read this manual will help you to prevent damage to the product, and, most importantly, personnel situated close to it. The product is designed to be safe when used correctly. However, there are many potential hazards associated with incorrect operation and these can be avoided when you know how to recognize and anticipate them. This manual is not intended as a substitute for proper training but provides recommendations and methods for safe and efficient service.

2.2

Symbols used in this manual

Readers should familiarize themselves with the following symbols which are used in this manual. NOTE: Indicates items which require special attention by the reader. There is no obvious risk of injury associated with notes.

2.3

Safety Alert Symbols and Signal Words

The following symbols are used in this manual to indicate potential safety hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

CAUTION

Indicates a potentially hazardous situation, which if not avoided, MAY result in minor or moderate injury. It may also be used to alert against unsafe practices.

WARNING

Indicates a potentially hazardous situation, which if not avoided, COULD result in death or serious injury.

DANGER

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.

NOTICE

Shall

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Addresses situations not related to personal injury, such as likely or possible damage to equipment.

Indicates that a rule is mandatory and must be followed.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Should

2.4

Indicates that a rule is a recommendation, the advisability of which depends on the facts in each situation.

Questions and Comments

Any questions or comments relating to the content of this manual and/or the operation, maintenance and/or service of manufacturer products should be directed to: www.rmhoist.com

2.5

Manual Use

Every person exposed to the manufacturer’s equipment must, prior to OPERATING, SERVICING AND/OR MAINTAINING SUCH PRODUCTS, read and understand the contents of this manual and strictly adhere AND CONFORM THEIR CONDUCT WITH AND TO THE INFORMATION, RECOMMENDATIONS AND warnings provided herein.

Note: Keep these instructions in a safe, accessible location for future reference by personnel operating the equipment or exposed to the equipment’s operation.

Read and understand the contents of this manual prior to operating, servicing, and or/maintaining the equipment. Failure to do so can result in serious injury or death.

Manufacturer shall not be liable for and owner and READER shall release, and hold manufacturer, harmless from any and all claims, demands, AND damages, regardless of their nature or type losses and expenses, whether known or unknown, present or future, any and all liability, of and from any and all manner of actions, cause[s] of actions, all suits in law, in equity, or under statute, State or Federal, of whatever kind or nature, third party actions, including suits for contribution and/or indemnity on account of or in any way arising out of acts or omissions of the Owner or READER and relating in any way to this MANUAL or THE PRODUCTS referenced herein, including, but not limited to the Owner’s or READER’S use thereof or any other cause identified herein or that may be reasonably inferred HEREFROM.

2.6

Service personnel

Only authorized service personnel or an experienced service technician authorized by the manufacturer may perform the detailed examinations necessary for scheduled maintenance. Such examinations must be performed in accordance with the inspection and maintenance plan provided by the product’s manufacturer. The original manufacturer has approved authorized service personnel to maintain its products. The owner or operator of the product must perform the daily checks and, if required, daily lubrication. Service personnel authorized by the owner may also lubricate the product at the necessary intervals. Note: Mechanical and electrical maintenance work requires special skills and tools to ensure safe and reliable operation of the product. Maintenance work shall be carried out only by authorized service personnel or an experienced service technician authorized by the product’s manufacturer.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

2.7

Terminology

The following terms and definitions may have been used in this manual: ANSI ISO Authorized personnel Experienced service person authorized by the manufacturer CE marking Check Emergency brake Electric panel Parking brake (storm lock)

Main brake Second brake (Holding brake) Operator Inching Bridge Main girder Main isolation switch Hoist Inspection (Visual)

Power supply Controller Qualified personnel

Maximum capacity Runway Trolley (hoisting unit) Sling

2.8

American National Standards Institute International Organization for Standardization Persons who are authorized by the owner and who have the necessary training to carry out operation or service actions. A person with service experience who is properly trained to perform service actions. The CE-marking indicates that the product complies with the appropriate CE regulations. A visual and functional assessment (not a test) of the product without dismantling. A brake that can be applied by the operator, or automatically upon loss of power. Power is controlled to the motors and components through the electric panel. A brake that can be applied either automatically or manually and prevents horizontal movement of the trolley or bridge. Used when movements need to be prevented in windy conditions. A brake that stops motion and prevents movements. A brake that supports the load if the main brake fails. Person operating the product for the purpose of handling or moving loads. Making very small movements by repeatedly and momentarily pressing the direction control. The bridge (main girder) moves along the runway The main girder (bridge) is connected to the bridge end carriages. The main isolation switch is the power switch which the operator should normally use to turn off the power. Drive mechanism for lifting and lowering the load. Looking for defects and checking the operation of the controls, limiting and indicating devices without loading the product. This is much more than a check but does not normally require any part of the product to be dismantled other than for removal or opening of covers or housings. Power is supplied to the components via the power supply. The pendant or other type of controller is used by the operator to give commands to the product. One with necessary qualification based on theoretical and practical knowledge of hoists or/and cranes. The person must be in a position to assess the safety of the installation in conjunction with the application. Persons with the authority to undertake certain maintenance work on products of manufacturers include manufacturers’ service engineers and trained fitters with corresponding certification. Load that the product is designed to lift for a given operating condition (e.g. configuration, position of the load). The product rides on or under the runway. The trolley (hoisting unit) moves along the main girder. A sling is used to attach the hook to the load when the load cannot be lifted directly by the hook.

Standards and Directives

This state of the art product has been designed and manufactured to conform to European and international standards and directives. The product also fulfils the requirements of the following standards (if applicable): CSA, UL, RoHS, OSHA, CCC.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

3

SAFETY FIRST!

Safety requirements must be understood and followed.

3.1

Personal protective equipment (PPE)

For safety, the service personnel or others in close proximity to the product may be required to wear Personal Protective Equipment (PPE). Various types of PPE are available and must be selected according to the requirements of the working environment.

Note: Follow the local regulations and requirements of the working environment.

3.1.1 Fall Protection

While personnel are performing inspection or maintenance work at heights, they must follow fall protection procedures as required by local regulations. Fall prevention practices and fall protection equipment aim to protect personnel working on or around the equipment from exposure to falls. If the equipment does not have a service platform or handrail, personnel must use a properly fitted safety harness that is attached to the dedicated fixing points on the building or equipment in order to prevent falls. If the product does not have dedicated fixing points for fall protection, it is the owner’s responsibility to make sure that there are suitable fixing points in the building structure. If ladders must be used, personnel must practice setting and securing the ladders before using them for actual work. A typical fall protection program may include:  Documented and established site policies and procedures.  Conducting site assessments for fall hazards.  Selection of the proper fall protection system and equipment.  Training on fall protection procedures and the proper use of fall protection systems.  Inspection and proper maintenance of fall protection equipment.  Measures to prevent falling objects.  Rescue Plans. If necessary, contact your supplier or service organization for assistance with designing your fall protection program.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

3.2

Fire Safety

In the event of a fire, only attempt to fight it if you can do so without putting yourself in danger. Turn the power off if it is possible to do so. Evacuate the area. Notify other people about the potential danger, and call for help.

WARNING

3.3

Main isolation switch

CAUTION

3.4

Never use a powder type fire extinguisher on high voltage.

Service personnel shall be aware of main isolation switch functionality. Eventhough one switch is turned off, there may still be voltage in some parts of the product. This may result in exposure to electric shocks.

Safety during maintenance

Before and during product maintenance, the following precautions should be taken by maintenance personnel:

1

Choose a safe working location The product should be moved to a location where it will cause the least disturbance and where it can be accessed easily.

2

Prevent unauthorized access to the site Prevent unauthorized persons and bystanders from walking on or below the work site. For example, you can lock doors, install barriers and display notices. Ensure that the secured area is spacious enough to prevent injuries which could occur as a result of falling components or tools.

3

Inform that equipment will be undergoing maintenance Before starting maintenance, people must be properly informed that the equipment is being removed from operation.

4

Ensure that there is no load on the lifting device Before starting maintenance there should be no load on the hook or lifting device. Park the hook on the ground if there is any chance that the hoisting brake will be opened during maintenance. A raised empty hook will fall to the ground if the hoisting brake is opened.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

5

Turn all controllers and main switches off All controllers and main isolation switches must be placed in the off position before starting maintenance.

6

Lockout – Tagout The product power source must be locked out and tagged out when necessary, in accordance with local regulations. See chapter “Lockout – Tagout Procedure”

7

Verify that power is completely disconnected Measure between the phases and between each phase to ground to ensure that power is completely disconnected from the product.

8

Use hand lines for lifting and lowering tools Hand lines, securely attached to the building structure, should be used for lifting or lowering materials and tools. Use proper safety equipment to prevent objects from falling when working in high places.

9

Safety devices must be restored to operational status Ensure that any safety devices which have been bypassed for testing purposes have been restored to full operational status before allowing the product to be used for normal operation.

10

Minimize the risks of moving machinery Secure the area so that personnel are not at risk from the movements of machines, automatic doors or adjacent cranes at the installation site. Ensure that machinery and equipment cannot start up accidentally and cannot move during installation and servicing. Be prepared in case equipment moves in the wrong direction during testing.

11

Perform regular inspections and preventive maintenance To ensure ongoing safe and efficient operation of the product, carry out regular inspections and preventive maintenance in compliance with the instructions. Keep a record of all inspections and servicing. If in doubt, contact the supplier of the product.

12

Returning the product to operation after overload or collision After an overload or collision incident, the appropriate inspection and repair operations must be discussed with the supplier of the product.

13

Pay special attention to all safety-critical components The brakes, limit switches, hook, rope and controller are all safety-critical items which must always be kept in good order. Ensure that safety devices (overload protectors, limit switches, etc.) work properly so that they provide protection against human error.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

14

Beware of high temperature components Some components of the product, such as the motors, can become very hot during use. Check that components are cool before working on them.

3.4.1 Lockout - Tagout Procedure

During installation, inspection and maintenance, lockout-tagout procedures must be followed in accordance with local regulations and the documented site lockout-tagout policy. The owner must ensure that the operators are fully aware of the applicable lockout - tagout practices. Lockout-tagout procedures are primarily intended to protect personnel by preventing accidental starting or exposure to electric shocks. Individual locks and tags are placed on controls to prevent their use until the person who installed the lock or tag removes it.

CAUTION

Never attempt to operate a control, switch, valve or other device when it is locked out or tagged out.

Items which are normally included in the documented lockout-tagout policy:  Communication requirements: who to inform before using lockout - tagout.  When the use of lockout - tagout is permitted.  Identification of each of the switches, controls, valves and other energy isolating devices present at the site. The role of each device should also be explained.  The lockout - tagout sequences to be followed before, during and after maintenance.  Safety and operational considerations regarding other products on the same runway or on adjacent runways.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc. Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

4

IDENTIFICATION

This manual contains information for several hoist types, components and options. The information in this manual is identified by individual feature of hoist or by product code or by part of product code. Identification data is on hoist data plate or component data plate.

4.1

Manufacturer

Manufacturer: Address:

R&M Materials Handling Inc. 4501 Gateway Boulevard 45502 SPRINGFIELD, OH USA

Note: For further information about the product, operational training or servicing, please contact the manufacturer or manufacturer’s representative.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

4.2

Hoist series

The series of hoist covers a lot of variants with load capacities ranging from 400 kg to 80 000 kg. It covers a whole range of modular hoists with numerous options under hoist components. The following illustration and the table after show in brief different modules/components available.

Pos.

Module or component Electrics

A 1

2

B C A Traveling machinery

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Description of modules of hoist series Several control device, driving device and measuring/monitoring device variants and combinations. • Controlling devices: push button pendant, remote controls etc. • Measuring and monitoring devices: condition monitoring, overload indication etc. • Driving devices: contactor controls, frequency controllers etc. • Several machinery sizes. Several motor and gear size variants and combinations. R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Pos. Module or component B C Hoisting machinery 3 A B Rope drum length 4 A B Trolley A B

5

• Several quantity variants on applications. Several machinery frame sizes. Several motor, gear and drum size variants and combinations. • From drum size Ø 243 mm. • Up to drum size Ø 608 mm with two motor drive. Several drum length variants. • Short drum lengths for short lifting hights. • Long drum lengths for long lifting hights. Single girder trolley variants: • Low headroom trolley • Normal headroom trolley

C C C C D

Double girder trolley variants: • Double girder trolley • Double girder trolley ,Low • Double girder trolley ,Medium • Double girder trolley ,High • Two hoist trolley

E E

Fixed connection variants: • Fixed hoist • Machinery hoist Reeving system

6

Description of modules of hoist series

A B C

4.3

Several reeving system variants: • Standard reeving • True vertical reeving • Machinery reeving

Hoist Identification Data

The hoist serial number is stated on the hoist’s data plate which is located on the trolley.

1 2 3 4 5 6 7 8 9 10 11 12 13

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Product Duty class Load Height of lift Approvals and standards Serial number Manufacturing month Manufacturer’s reference Frequency Hoisting speed Trolley speed Main voltage Control voltage

Exact model of the product, product code. Duty group defined based on the expected use of the product Maximum load which can be lifted with the product Maximum lifting height of the hook Directives and approvals which the product complies to. Refer to the chapter “Standards and directives”. A unique number which identifies the product Manufacturing month/year Factory work number Supply frequency which the product is designed for High/low hoisting speed High/low trolley travelling speed Supply voltage which the product is designed for Control circuit voltage

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Note: The example data in the above figure is shown for illustration purposes only and does not match the data on your product.

4.4

R&M code example (R&M: SX, Factory: Q) SX

2

041

0020

P

1

5

F

A

L0

N

1,2

(GE09) 3

(DES27) 4-6

(LOA01) 7-10

(HM01) 11

HM02 12

(DIM01) 13

HS06 14

GE08 15

(DES01) 16,17

18

Pos. Code 1,2

3

Short product name

SX

2

4-6

041

7-10

0020

11

P

12

1

13

5

14

Feature Feature code

F

(GE09) Frame size

(DES27)

Rope reeving code

(LOA01) Capacity (HM01) Hoist motor type

HM02

Hoist motor size

(DIM01) Hoist duty group

HS06

Hoisting gear type

Available properties SX SX product 1 2 3 4 5

243 mm rope drum diameter 303 mm rope drum diameter 303 mm rope drum diameter 355 mm rope drum diameter 406 mm rope drum diameter

1-roped 010 021 031 041 061 081

GE09 value Z 6 A 7 A B C

DES27 value 01 02 03 04 06 08

608 mm rope drum diameter 608 mm rope drum diameter (2 hoisting motors)

2-roped 022 042 062 082

GE09 value D E

DES27 value 22 24 26 28 M1 A2 B2

Capacity x 100 (units: kg or Lbs.), 0020 x 100 = 2 000 kg, 2000kg = LOA01 HM01 value P I

P

Pole change motor

1 2 3 4 5 6

50 Hertz 1.8 kW 3.6 kW 4.5 kW 7.5 kW 9 kW 15 kW

3 4

ASME / ISO Duty class H2 / M3 H3 / M4

E F G H J

Hoist speed for 4-roped, 50 Hz 4 m/min 5 m/min 6.3 m/min 8 m/min 10 m/min

7 8 9 A X Z DIM01 value M3 5 M4 6

Frequency converter motor

HM01 value T

50 Hertz 18 kW 23 kW 28 kW 35 kW 1.5 kW 2.5 kW ASME / ISO Duty class H4 / M5 H5 / M6

DIM01 value M5 M6

Hoist gear options listed are not available for all hoist frame sizes.

15

A

GE08

A B C D Hoist drum length E F G H

310 mm rope drum length (if frame size 1, 394 mm) 340 mm rope drum length (if frame size 1, 394 mm) 440 mm rope drum length (if frame size 1, 504 mm) 540 mm rope drum length 660 mm rope drum length 810 mm rope drum length 1000 mm rope drum length 1250 mm rope drum length

J K L M N Z X

1600 mm rope drum length 1900 mm rope drum length 2250 mm rope drum length 2500 mm rope drum length 2800 mm rope drum length 1400 mm rope drum length Special drum length

L0 N0 D0 F0

Low headroom Normal headroom Double girder (standard) Foot mounted

S

Special hoist

Drum lengths are available for hoist frame sizes indicated. DES01 value 16,17

18

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L0

N

(DES01) Trolley type

Special properties

NP Normal headroom perpendicular DH Double girder (Height above rail is taller than standard, improves HR) DL Double girder (Height above rail is lower than standard, increases HR) N F

Standard hoist without any options Options selected from option list

H

DES01 value L N M F

W

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

4.5

Motor Identification Data

Motor serial number and other motor information such as motor type are stated on the motor rating plate which is located on the motor.

Hoisting motor

Note: Hoisting motor data plate may also be located on the side plate of the hoist/trolley.

A B 1 2 3 4 5 6 7 8 9 10 11

Motor rating plate Bar code sticker Motor type code Motor serial number Input Output Phases Approvals and standards Factory work number Motor type code Reference numbers Identification number Bar Code

Product identification data Product order references Exact model of the product Unique number which identifies the unit Acceptable main voltage range and frequency that the product can be connected to Voltage range the product is able to provide at a specified output capacity Phase quantity of the motor Directives and approvals which the product complies to. Refer to the chapter “Standards and directives”. Motor factory work number Exact model of the product Order related numbers Identification number of the motor, this number used when ordering spare parts Bar code which includes, for example, the product’s serial number and ID in an optically readable form

Note: The example data in the above figure is shown for illustration purposes only and does not match the data on your product.

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Traveling motor

A B 1 2 3 4 5 6 7 8 9 10 11 12

Motor rating plate Bar code sticker Motor type code Motor serial number Input Output Phases Approvals and standards Factory work number Motor type code Reference numbers Motor number Bar Code Identification number

Product identification data Product order references Exact model of the product Unique number which identifies the unit Acceptable main voltage range and frequency that the product can be connected to Voltage range the product is able to provide at a specified output capacity Phase quantity of the motor Directives and approvals which the product complies to. Refer to the chapter “Standards and directives”. Motor factory work number Exact model of the product Order related numbers Unique number which identifies the unit Bar code which includes, for example, the product’s serial number and ID in an optically readable form Identification number of the motor, this number used when ordering spare parts

Note: The example data in the above figure is shown for illustration purposes only and does not match the data on your product.

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5

GENERAL ABOUT MAINTENANCE

Maintenance actions, excluding the daily actions performed by operators, must be done by service personnel who are authorized by the product manufacturer.

WARNING

Do not modify the product without the manufacturer’s permission. Any modifications to the product structures or performance values must only be made after they have been approved by the product’s manufacturer.

WARNING

Do not allow the product to be used if it is not in proper condition. The usage of a defective product can result in serious damage, injury or death.

CAUTION

Only use genuine spare parts, materials and lubricants approved by the product’s manufacturer.

CAUTION

Never wash the crane or hoist with chemical products or high pressure water jets, as they can cause problems like detaching of the stickers and water entering inside the electrical components.

For installation and commissioning instructions, refer to the separate manual: “Installation and Commissioning for Hoist”.

5.1

Service process

Service process should include following steps.

1

Preliminary actions This may include: • Prepare schedules, process plans and documentation. • Reserve sufficient resourses like properly trained personnel, enough time and apporiate tools. • Plan safety actions and reserve proper safety equipment.

2

Examination of usage and service history This may include document reviews and discussions with Owner and Operator: • Check Log book for service actions and plans enlisted. • Observe the intended use and cahanges of usage with Owner and Operator. • Collect Owner’s and Operator’s experiences and observations like unusual or irregular operation of the equipment.

3

Inspection Carry out independent inspection to assess the condition of the product. Note down all irregularities not present in previous records. Carry out all inspections including daily inspection and periodic inspections according to maintenance program.

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4

Maintenance and service This may include testing, adjusting, lubricating, repair and replacement work. Investigate root cause of the problems, if any and inform the owner/operator of the recommended repair or replacement.

5

Conclusion Do conclusions with Owner and Operator based on collected information during service process. These may result further actions like shortened service intervals or proposal of product update.

6

Documentation and feed back This may include: • Update of logbook and other product documentation. • Training about operation and daily maintenance.

5.2

Periodic inspections and actions

Periodic inspections must be carried out by authorized service personnel or experienced service technician authorized by the product’s manufacturer. Inspections must be carried out according to manufacturer’s instructions.

Note: If the working environment or product usage changes, the inspection and maintenance intervals may need to be revised.

Note: Periodic inspections SHALL be carried out in accordance with local regulations.

CAUTION

Any defects or abnormalities which are detected during the inspections must be investigated and corrected in accordance with the instructions relevant to component in question.

5.2.1 Daily inspections Daily inspection items are listed in Hoist Operator’s Manual. In most cases these checks will be performed by operators on start of each work shift. Check if there is need for other daily checks caused by application, usage, product options, environment or some other reasons. Update Operator’s instructions if needed.

5.2.2 Periodic inspections and maintenance tasks Carry out the inspection and servicing procedures for the hoist in accordance with the maintenance program. Check if there is need for other periodical maintenance tasks or need to shorten the intervals caused by application, usage, product options, environment or some other reasons. Update Owner’s and Operators instructions if needed. 19/218

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

Note: Product used under harsh conditions may require shorter service intervals.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

5.3

Approaching Theoretical Calculated Lifetime

In order to ensure safe operation of cranes, the proper working and operational condition shall be maintained according to standard ISO 9927. This requirement covers also special assessments to be carried out by an expert engineer at regular intervals to check the remaining Safe Working Period (SWP) of the hoist as stated in standard ISO 12482-1. The condition monitoring unit (CID) provides two different SWP values: the runtime-based SWP (CID parameter 212 SWPRT% ) and the working cycle-based SWP (CID parameter 2-15: SWPHC%). The CID display of the data counter SWP always shows the lesser value of two parameters.

5.3.1 General Overhaul In the GO service, the product is assigned with a new, runtime-based SWP, provided that it is safe to continue the operation. The runtime-based SWP means the lifetime of the interchangeable rotating components of the hoist like hoisting gear, hoisting motor, and rope sheaves. Note that in case of hoists with a smaller drum size, it is often more cost-efficient to replace the hoist with a new one.

WARNING

CAUTION

When the Safe Working Period (SWP) of the hoist has decreased to zero or is counting in the negative, the hoist may only be used after a GO service has been conducted, or the hoist must be replaced with a new one. Any usage of a defective hoist can result in serious damage, injury, or death.

When performing General Overhaul, the construction of the hoist may not be changed or the supporting structures repaired without permission from the manufacturer. If there are any deformations, cracks or corrosion in the supporting structures of the hoist, the parts have to be replaced or repaired according to the instructions given by the manufacturer.

Only authorized service personnel or an experienced service man that is authorized by the manufacturer or manufacturer representative may conduct a General Overhaul service. The following figure summarizes the conditions based on which General Overhaul can be performed.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

The same hoisting machinery can undergo no more than two GOs before it must be replaced completely:

SWP = Safe Working Period RSWP = Runtime-based Safe Working Period GO1 = First General Overhaul GO2 = Second General Overhaul T = Time

For more information, refer to “General Overhaul Instructions”.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

6

MAINTENANCE PROGRAM

The lifetime of the hoist is divided into Safe Working Periods (SWPs). At the beginning of the Safe Working Period, a new hoist has an SWP% of 100. A Safe Working Period ends when the SWP% of the hoist is zero. When a Safe Working Period ends, a General Overhaul (GO) must be conducted, after which the hoist is assigned a new Safe Working Period, refer to the section 'General Overhaul, GO'. During the SWP, the safe and efficient operation of the hoist is contingent on regular servicing.

6.1

CAUTION

For the safety carry out the inspection and servicing procedures for the hoist in accordance with maintenance task list.

CAUTION

To avoid any risk of spark with explosive proof hoists due to the friction of two mechanical parts, it is important to follow strictly the maintenance intervals. The safety of the equipment could be compromised if not.

Periodic inspections and maintenance tasks

The servicing intervals for the hoist are defined as SWP% periods. The actual operation of the hoist is taken into account in SWP%. If the hoist is provided with a condition monitoring unit, the SWP value can be read from the unit display. Refer to the more detailed instructions that are given in the separate operating instructions for the condition monitoring unit. The following table shows the service intervals for the hoist in SWP% periods and in calendar months. The servicing procedure must be carried out at the end of SWP% period latest, or after the stated number of calendar months. Hoists without a condition monitoring unit must follow a servicing procedure guide by calendar months. For ensuring the usability of the hoist, the servicing intervals can be shortened.

CAUTION

Hoists used under harsh conditions may require a shorter servicing interval than stated in the table. Consult with a representative of the manufacturer for a tailored service agreement.

CAUTION

If ambient temperature is frequently over 40 ºC (104 F), the servicing interval is half of the interval that is stated in the following table.

CAUTION

If the hoisting machinery is used outdoors, the lubrication of all the hoisting machinery parts, as a general rule, should be carried out on a quarterly basis (every three months).

WARNING

Periodical inspecting and servicing procedure may only be carried out by a serviceman authorized by the hoist manufacturer, or by the service personnel that are adequately trained by the hoist manufacturer.

Note: Intervals on the following table are SWP% periods or a stated number of calendar months. For ensuring the usability of the hoist, the servicing intervals can be shortened.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

General Inspection and maintenance task Interval

Component

Hoist

Stickers and markings

Interval is SWP% reduction or calendar months

10% 12

Test-run the hoist first to see that all movements (hoisting, traveling) function smoothly without any unusual noise or vibration.

10% 12

Inspect the general condition and cleanness of the hoist. Visually check the general condition and accumulation of dust or dirt. Pay special attention to: • Hoist motor body. Remove dust or dirt to eliminate insulating factor, as the motor heat must be able to dissipate • All parts that need cooling • Parts that wear if the surfaces are not clean • Optical and other sensors. Inspect the condition and fixing of covers. Test by hand that all covers are fixed. Visually check that covers are not bent or cracked. Fix or replace if needed. Inspect the condition and readability of warning stickers and other See sections: stickers and markings. Hoist identification data Visually check that all type plates and stickers exist and are readable. Motor identification data Replace all missing and unclear stickers. Check that the capacity load of a hoist is readable on the hook block.

10% 12

Capacity labeling

Instructions and log books

See further instructions

10% 12

10% 12

Check the availability and readability of instructions. Visually check product documentation. Verify that the user and owner are aware of the documentation and it is available for them. Replace all missing and not readable documentation. Check the validity of log book. Update the log book during the service process.

Limiting devices Inspection and maintenance task Interval

Component

Interval is SWP% reduction or calendar months

Trolley buffers (Bumpers)

10% 12

Inspect the condition of trolley buffers and buffer end stops Verify that buffers (bumpers) make contact at the end stops. Replace worn or broken buffers.

Trolley traveling limit switches

10% 12

When installed, check the operation o f the slowdown limit of a trolley. When installed, check the operation of the stop limit of a trolley.

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See further instructions

Maintenance of trolley buffers

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Inspection and maintenance task Interval

Component

Hoisting limit switches Up Limit

10% 12

Interval is SWP% reduction or calendar months Verify the condition and operation of hoisting limit switches. Operate the hoist in the up direction and slowly drive to the Up Limit Switch Activation point. Check that it works.

Slow Down Up Limit

Run the hook block down at a short distance and drive at high speed and check if the Slow Down Up Limit activates to override the highspeed command to slow down the speed before the Up Limit activates.

Down Limit Hook limit (Safety Up Limit/ Ultimate Limit)

See further instructions

Construction of hoisting limit switch for hoist frame size: SX1 Construction of hoisting limit switch for hoist frame size: SX2, SX3, SX4, SX5, SX6, SX7 Maintenance task for hoisting limit switch, hoist frame size: SX1 Maintenance task for hoisting limit switch, hoist frame size: SX2, SX3, SX4, SX5, SX6, SX7

Operate the hoist in the down direction and drive to the Down Limit Switch Activation point. Test the Hook Limit by hand actuation.

Up Limit Distance

10% 12

Down Limit Distance

10% 12

Overload protector

10% 12

Adjust or replace parts as required. Verify Up Limit Distance. Verify the Up Limit Distance to the frame of the trolley. It is important to adjust the C dimension according to the specification, to minimize rope and sheave wear. Verify Down Limit Distance. When the hook block is in the Down Limit Switch Activation point, verify that there is a minimum number of wraps of rope on the drum according to the standards (the absolute minimum is two full turns of a rope). Inspect the condition and operation of the overload protector. Overload protection Maintenance of overload device Mechanical switch and load sensor overload device: Operation test of overload Test the free movements of mechanical parts. Test the mechanical overload limit switch by mechanically activating the switch and checking for a click. Clean and lubricate lever mechanism. Verify that the set screw is locked in its place. When required to confirm calibration, place a test weight of a nominal load plus 10%. Adjust mechanical overload to stop hoisting at 110% of capacity. Replace damaged parts.

10% 12

Power measurement overload device: Conduct a test operation of the power measurement overload device according to the local regulations if necessary. Verify the operation of the condition monitoring unit. Test the condition monitoring unit by lifting a known load and verify that the unit reads the load within 5% accuracy. If not reading properly, a new calibration of the unit required. Check for possible error codes and warnings.

Condition monitoring unit

Service manual for hoist control device

Runway mechanical Inspection and maintenance task Interval

Component

Crane runway rail

25/218

See further instructions

Interval is SWP% reduction or calendar months Inspect the crane runway rail. • Check the bridge squareness • Check that both end trucks are working simultaneously in the starting and the stopping phases • Monitor for possible sounds of grinding or any unsmooth travel of the bridge along the runway • Visually check the straightness • Check rail fastenings randomly for possible loose connections • Check the rail for any signs of wear.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Inspection and maintenance task Interval

Component

Crane runway end stop

See further instructions

Interval is SWP% reduction or calendar months Inspect the crane runway end stops. Inspect the end stops for wear, cracks, or deformation. Inspect the runway end stop fastenings. The end stops are to be in parallel position.

Runway electrics WARNING

Inspection and maintenance task Interval

Component

Switch off the power to the runway before you carry out the inspection.

Crane power supply collectors

See further instructions

Interval is SWP% reduction or calendar months Inspect the power collector shoes. • Check for any signs of wear • Check that there is a proper contact between the shoes and the conductor bar • Check the spring tension of the collector Inspect the collector bar. • Check straightness • Verify that the fasteners are fixed properly • Check the bar for possible signs of wear: burn marks, oxidation, cracks, or any other general damage. Inspect the main isolation switch (the main runway disconnect switch). Verify the following: • Main isolation switch is labeled to indicate what crane runway it controls • Main isolation switch functions properly • Main isolation switch is lockable.

Main isolation switch (Main runway disconnect switch)

Inspect the fuses and the holder of fuses. Verify the following: • Fuses are secure • Holder has no corrosion • Wiring to the holder is secure.

Bridge mechanical Inspection and maintenance task Interval

Component

Bridge capacity labeling

See further instructions

Interval is SWP% reduction or calendar months Verify that the capacity load of the crane bridge is readable by the crane operator.

Bridge buffers (bumpers)

10% 12 10% 12

Bridge end truck connection

10% 12

Bridge gearboxes

10% 12

Bridge wheels

10% 12

Check the connection for • possible cracks • missing bolts • loose bolts. Inspect the gearboxes. • Check that the fastenings are secure • Look for possible signs of leakage • Inspect oil level if possible • Verify the tightness of the gearbox output shaft fastening to the wheel shaft. Inspect the bridge wheels. Check wheels for possible flange wear. Lubricate the bridge wheels.

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Inspect the condition of bridge buffers and buffer end stops. Verify that buffers (bumpers) make contact with the end stops of the bridge at the same time.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Inspection and maintenance task Interval

Component

Bridge rail sweeps

10% 12

See further instructions

Interval is SWP% reduction or calendar months Check the condition of bridge rail sweeps for any signs of wear and replace them if necessary.

Bridge electrics Inspection and maintenance task Interval

Component

Bridge travel limits Bridge power supply

10% 12 10% 12

Bridge disconnect switch

10% 12

See further instructions

Interval is SWP% reduction or calendar months Check the operation of Slowdown and Stop Travel Limits of the bridge. Check the festoon cable system. • Check that the cable is not worn • Verify that the cable is running smoothly from one end of the bridge to the other end, indicating that the cable carrier is not damaged and the cable is not running into any obstacles • Check that the pull cable is secure and working properly, relieving strain on the cable when the trolley is pulling • Check that the festoon arm is secure. Verify that the bridge disconnect switch on the bridge panel turns on and off the power.

Electrics Inspection and maintenance task Interval

Component

Emergency stop

10% 12

Main switch for hoist

10% 12

Wiring

10% 12

Hoist cubicle

10% 12

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See further instructions

Interval is SWP% reduction or calendar months Check that the emergency button is clean and not damaged. Push in the emergency button. Test that no movement activates. Verify that the main contactor is off. If the emergency stop is equipped with key locking, remove the key and test that it is not possible to release the emergency stop. Check that the main switch is clean, clearly marked and not Main isolation switch damaged. Test manually that the main switch switches off the hoist. Inspect the condition of wiring and the connections. • Follow the power supply and visually check the potential areas for damages • Pull on the wiring at the terminals • Check the wiring for any signs of wear, crushing, breaks, or cuts • Check visually that the cable bushings are tight • Check visually that the connectors are not damaged • Test by hand that the cable bushings are tight • Test by hand that the connectors are tight • Check randomly the tightness of screws at the terminal blocks and at the connections of other components. Note that the terminals can cause a heat damage to the insulation and/or to the connections. Check that the electrical cubicle is securely fastened with a trolley or a bridge. Verify that the doors are closing properly and the locking devices are functioning. Check the door sealing. Check that the cubicle is clean. Inspect the air conditioning and filters. Inside the electrical cubicle: • Check that the electrical components and their fastenings are secure. • Check that all the electrical protection guards are in place.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Inspection and maintenance task Interval

Component

Contactors

Condition monitoring unit warning “Control"

Over-current protectors Fuses

Braking resistors (with some frequency converter models) Hoisting frequency converter

See further instructions

Interval is SWP% reduction or calendar months

Control Check that all the movements are operational in the hoist, in the Contactors warning trolley and in the bridge. Check visually that the contactors are clean and there are no visible 12 damages. When the condition monitoring unit indicates the “Control” warning, one of the start counters 2-7 (ST up), 2-8 (ST down) or 2-9 (ST fast), has reached the set design limit (the default value is 640,000 operations) which is defined with parameter 6-19 (Max Control) that calculates the lifetime of the contactors. When the design limit has been reached, replace the contactors (Up, Down, Slow, Fast and Brake Contactors). If a brake contactor contains an auxiliary contact block or a time delay auxiliary contact block, replace that part as well. After the replacement, calculate a new value for parameter 6-19. See instructions in chapter “Contactors”. If the condition monitoring unit is not used with the hoist, replace the contactors after six years of operation according to the designed duty cycle. Check the adjustment of the over-current protectors. 10% 12 Inspect visually that the fuse holder and the fuses are clean and 10% there are no visible damages. 12 Check the correct amperage rating. Clean all dust or dirt from the braking resistors. 10% 12 10% 12

Check that wires are securely fastened. Check fault code records. Inspect the operation and cleanliness of the cooling fan.

See further instructions in the equipment-specific “Service Manual for Frequency Control System”

Traveling frequency converter

10% 12

Check that wires are securely fastened. Check fault code records. Inspect the operation and cleanliness of the cooling fan.

See further instructions in the equipment-specific “Service Manual for Frequency Control System”

Frequency controller

10% 12

Check fault code records. Verify that the frequency converter fan is working. Check that the frequency drive is clean from dust or dirt. When the condition monitoring unit indicates the “Control” warning, the design limit (the default value is 640,000 operations) has been reached. Replace the brake timer block, the brake contactor as well as the brake control PC board that contains the brake relay (in ControlMaster Plus Hoisting (CMPH) / ControlMaster Elite - Hoisting (CMEH) frequency converters, replace the B board).

See further instructions in the equipment-specific “Service Manual for Frequency Control System”.

10% 12

Check that the radio receiver is working normally.

ControlMaster Plus - Hoisting (CMPH) / ControlMaster Elite - Hoisting (CMEH) Condition monitoring unit warning “Control” Radio receiver

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Motors and gears Inspection and maintenance task Interval

Component

Hoisting motor

10% 12

Traveling motor

10% 12

Hoisting brake

10% 12

Traveling brake

10% 12 20% 24

Hoisting gear

10% 12

Traveling gear

10% 12

See further instructions

Interval is SWP% reduction or calendar months Inspect for any unusual noise or vibration. Drive and check that the hoisting motor operates properly when loaded. Verify that the cooling fan is working properly. Clean the cooling ribs surface from dust and dirt. Check that all motor fastenings are tight and the motor is properly on its position. If the bolts are loose, tighten them to the proper torque. Inspect for any unusual noise or vibration. Verify that the cooling fan is working properly. Clean the cooling ribs surface from dust and dirt. Check that all motor fastenings are tight and the motor is properly on its position. If the bolts are loose, tighten them to the proper torque. Check that there is no visible damage. Check that the outside surface of the brake is clean. Drive with nominal load and test that lifting and lowering brake smoothly and the braking time and distance is acceptable. Disassemble the hoisting brake: • Measure disk pad thickness • Inspect the center hub teeth for cracks or any wear. Replace it if worn • Replace the disk when its condition is not complying with specifications • Clean the inner side of the brake from dust and dirt. • When the maximum allowed number of braking actions has taken place (CID Warning: Br SWP %), replace the hoisting brake and the hoisting coupling. Check also the condition of coupling splines in the motor shaft and in the gear shaft. Inspect that there is no visible damage. Check that the outside surface of the brake is clean. Drive with load and test that brake operates smoothly and the braking time and distance is acceptable. Disassemble the traveling brake: • Measure the air gap, clean, and adjust the brake if needed • Measure the brake pad. Replace it if necessary.

Check that the gearbox fastenings are secure. Inspect the gearbox for possible lubrication leakage. If there is an excessive leakage, open the gearbox and replace the sealings. Test the gear running sound and vibrations with load. Check that the breather-plug is free of dust and dirt. Check the temperature of the hoisting gearbox by hand. Check the oil level if an oil-filled hoisting gear. Check that the gearbox fastenings are secure. Inspect the gearbox for possible lubrication leakage. Check visually the torque support mounting and the rubber bushing if present. Test the gear running sound and vibrations with load. Check that the breather-plug is free of dust and dirt. Check the temperature of the traveling gearbox by hand. Check the oil level if an oil-filled traveling gear.

Hoisting motor Maintenance of hoisting motor

Traveling motor

Hoisting brake Replacement of a hoisting brake

Construction of compact brake for traveling motor MF06 Construction of DC brake for motor MF06LB* or MF06 two-speed Construction of DC brake for motors MF07 and MF10 Maintenance of traveling brake, compact brake Maintenance of traveling brake, DC brake for motor MF06 Maintenance of traveling brake, DC brake for motors MF07 and MF10 Hoisting gearbox Lubrication

Traveling machinery Maintenance of traveling machinery unit Lubrication

Open transmission: • Inspect the open transmission visually for wear • Lubricate the open transmission. 29/218

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Inspection and maintenance task Interval

Component

Motor/gear coupling

*)

See further instructions

Interval is SWP% reduction or calendar months Investigate the condition of the coupling between the motor and the gear. Hoisting gearbox The coupling must be replaced if there is any visible damage or rust Maintenance task for hoisting gear inside the coupling or if the o-rings have any visible damage or signs Lubrication of aging. Lubricate the coupling and motor splines carefully. *) Interval Hoist classification SWP% reduction Calendar period. Years

M5/M6 40% 4

M3/M4 80% 8

Mechanical component Inspection and maintenance task Interval

Component

Rope drum

10% 12

10% 12

Interval is SWP% reduction or calendar months Rotation of a rope drum and the condition of bearings: Check the proper rotation of a drum and the condition of bearings. Drive with and without load. Pay attention to the running sound of the rope drum bearings and check that the rope drum does not touch with the machinery end plates or other parts.

Axial locking part on certain frame sizes: Inspect the condition and operation of the axial locking part. The axial locking part must be replaced when worn 5 mm or more. Clean and lubricate the locking part groove.

10% 12

Inspect the fixing of the connection rods: Check visually that the connection rods are straight and the fixing screws are tight.

10% 12

Check the gear rim. Check the gear rim for possible unusual noise during operation. Lubricate the gear rim. Inspect the condition and correct fastening of rope clamp. Check that the rope clamp bolts are tight. Ensure that there are friction turns when the hook is at the lowest position. Ensure that the rope end protrudes from the last clamp to the specified length. Inspect the condition of the rope guide. Test the proper operation of the rope guide. Inspect the rope guide for loose or missing fittings. Check the condition of the pressure bearing if present. Clean the rope guide guiding rod. Replace the worn parts. Lubricate the rope guide and the rope guide guiding rod. Inspect the condition of the rope. Inspect the rope for • broken wires • kinks • wear • dryness (lubricate if necessary).

Rope guide

10% 12

Wire rope

10% 12

Rope drum Maintenance tasks for rope drum Drum wear inspection Rope clamps Lubrication

Lubricate the drum bearings on both sides of the drum if not life- time lubricated. Inspect the condition and cleanliness of rope drum. Check visually the grooves of the drum. Measure the groove wear if needed. Clean and lubricate the drum surface.

10% 12

10% 12

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See further instructions

Rope guide Replacing an old style rope guide with a heavy-duty rope guide Lubrication

Wire rope Maintenance of wire rope Replacing the wire rope Discard criteria of wire rope Lubrication

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Inspection and maintenance task Interval

Component

Rope anchorage on drum

10% 12

Rope anchorage on dead end

10% 12

Rope reeving

10% 12

Rope sheaves (upper sheaves)

10% 12

Hook block

10% 12

Cross bar

10% 12

Hook safety latch

10% 12 10% 12

Hook forging

31/218

See further instructions

Interval is SWP% reduction or calendar months Inspect the condition and correct position of a rope anchorage. Check that the rope clamp nuts are tight. Ensure that the rope has not slipped in the rope anchorage by comparing to the nominal measurements. Make sure that the rope end protrudes from the rope anchorage as specified. Inspect the condition of the wire rope near the rope anchorage. Inspect the anchorage shaft locking. Inspect the condition of a rope sheave support and a rope anchorage support. Check that the sheave support shaft(s) are correctly in their slots and correctly locked. Lubricate the pivot bearing surfaces of the rope anchorage if needed. Ensure that the rope is assembled inside the rope anchorage correctly. Check that the wire rope clips have correct tightness and proper orientation. Inspect the rope reeving assembly. Lift up the hook and lower it down. Pay attention to the following issues: • Check if the hook block tries to rotate (remove the rotation by reassembling the end fixing and by rotating to the opposite direction) • Inspect that the reeving balancing tilts freely (in two rope systems) • Verify that the rope moves smoothly over all sheaves and trough the rope guide • Ensure that the rope is tight and properly laid on drum grooves. In true lift hoists, it is normal that the hoisting causes the hook block to rotate. Inspect the condition of rope sheaves. Measure the rope sheaves to check if any wear. Inspect during operation if any unusual sound is coming from sheave bearings. Check the condition of the rope sheave support structure. Check that the sheave support shafts are correctly in their slots and correctly locked. Inspect the sheave support shaft fixing plate for any cracks (some Low Headroom Trolley models). Replace the support shaft by the latest construction/parts if not done yet (some Low Headroom Trolley models). Check the operation and condition of the hook block. Check the following: • The labels/stickers exist and are readable • The covers are not bent or damaged and do not touch to sheaves or rope • Lubricate all lubrication points. • Lift an empty hook and test that: • The hook does not rotate. • The empty hook does not tilt. • Test that the rope runs smoothly on sheaves with and without load. Check the condition of the cross bar hinge by tilting the hook forging. Check the condition of the hook thrust bearing by rotating the hook forging. Lubricate the cross bar hinge bearings using the grease nipples (hinged cross bars only). Lubricate the hook thrust bearing using the grease nipple, or open the cross bar if there is no grease nipple. Test by hand that the safety latch is not damaged and the spring keeps it closed. Inspect the condition of hook forging. Measure the hook forging opening if needed.

Rope anchorage Inspections and criteria for rope anchorage

Rope reeving system

Wear inspection of sheaves Maintenance of rope sheaves Sheave support and rope anchorage support

Hook block

Lubrication

Hook opening

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Inspection and maintenance task Interval

Component

Trolley wheels

10% 12

Trolley rail sweeps

10% 12

Load carrying structures

10% 12

See further instructions

Interval is SWP% reduction or calendar months Inspect the condition and cleanliness of trolley wheels. Check the trolley wheels for possible wear in the trolley wheel surfaces and flanges. Check the adjustment of rail width or rail gauge and measure. Clean the wheel and its running surfaces from grease and oil. Replace the worn parts. Test trolley wheel operation. Drive the trolley with and without load. Pay attention to the running sound of bearings. If necessary, lift the trolley and test by hand the free and smooth rotation of trolley wheels. Check that the wheels are correctly aligned and inspect for possible wear that is caused by misalignment. Lubricate the bearings if needed and possible. Check the condition of trolley rail sweeps for any signs of wear and replace them if necessary.

Construction of single girder trolley wheels Construction of double girder trolley wheels Maintenance of single girder trolley wheels Maintenance of double girder trolley wheels Wearing limits of single girder trolley wheels Wearing limits of double girder trolley wheels

Check the condition of bolted joints and load carrying structures. Visually check the bolted and welded connections of the security and backup components like a derailment catch.

Trolley Maintenance of double girder trolley structures Maintenance of single girder trolley structures

Anti-collision devices Inspection and maintenance task Interval

Component

Photoelectric anticollision device

10% 12

Ultrasonic anticollision device

10% 12

See further instructions

Interval is SWP% reduction or calendar months Inspect the condition and operation of the photoelectric anti-collision device. Clean the optical interfaces. Check the screw connections. Check the plug-in connections. Inspect the operation of the photoelectric anti-collision device. Inspect the condition and operation of the ultrasonic anti-collision device. Clean the sensor off thick layers of dirt and caked-on dirt. Inspect the operation of the ultrasonic anti-collision device.

Controls Inspection and maintenance task Interval

Component

Pendant

10% 12

Radio

10% 12

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See further instructions

Interval is SWP% reduction or calendar months Check the condition and functionality of push buttons and switches. Check all markings and signs that they are readable. Drive all movements. Test all functions. Change buttons/joystick or the whole pendant if needed. Check the condition and functionality of push buttons and switches. Check all markings and signs that they are readable. Drive all movements. Test all functions. Change buttons/joystick or the whole pendant if needed. Replace the battery if needed.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Options Inspection and maintenance task Interval

Component

Drum brake

10% 12

See further instructions

Interval is SWP% reduction or calendar months Inspect the condition and cleanliness of the drum brake. • Check that the brake bands are in correct position. • Check that the cam spring is in good shape. • Check that the actuator mechanism is clean and moves freely. Test that the cam operates correctly when lifting and lowering. Test that the limit switch stops the motions. Lubricate the actuator and the cam mechanism if necessary. Inspect the condition and cleanliness of the second brake. Inspect that there is no visible damage in the brake. Check that the outside surface of the brake is clean. Test that the second brake operates after the main brake. Check that lifting and lowering brake smoothly and braking time and distance is acceptable. If needed, inspect the brake disk and clean the brake.

Second brake

10% 12

Manual brake release for hoisting motor

10% 12

Note the correct torque of the fixing screws of the brake. Check that the manual brake release tools are available. Check that the operating instructions are available.

Manual crank

10% 12

Check that the manual crank and brake release tools are available. Check that the operating instructions are available.

Hook operated hoisting limit switch

10% 12

Inspect the condition of a hook operated limit switch. Inspect the wiring. Test the proper operation of the hook operated hoisting limit switch.

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Construction of holding brake Construction of overspeed brake Maintenance of holding brake Maintenance of overspeed brake Service after an emergency braking – In case an overspeed occurs

Second brake Maintenance of second brake Appendix: tightening torques

Manual brake release for hoisting motor Manual crank

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

6.2

Lubrication

6.2.1 General Lubrication Instructions Note: Most of the bearings in the product have lifetime lubrication. There is no need to add lubricant to the life time lubricated bearings under normal operating conditions.

Note: If transmission oil has to be topped up, make sure that the lubricant being added is compatible. If transmission oil has to be replaced, flush out the gearbox before refilling.

The following table provides advice on the lubrication procedures which should be followed.

1

Usage of a low grade or incompatible lubricant can damage the gearing or bearings. Use only lubricants recommended by the product’s manufacturer. See the lubricant tables for more information. Use only fresh oil/grease. Different kinds of lubricants shall not be mixed. Information about each chemical’s safe handling , risks and handling as waste are described in the Safety Data Sheet that is available from manufacturer of the lubricant.

2

Note: equipment may have synthetic lubricant as a factory installed lubricant. Please refer to order confirmation. Handle lubricants carefully. Prevent leakages to waters, sewers, cellars and other closed places.

3

Keep lubricants away from heat and open fires. Do not smoke when handling lubricants.

4

Avoid contact with skin. Protection gloves and safety goggles shall be worn when handling lubricants. Hands shall be washed thoroughly after lubrication.

5

Keep lubricants away from food and drink. Do not inhale any fumes or swallow lubricants.

6

Used lubricant shall be handled as hazardous waste following local legal requirements. Store used lubricant in containers indicated for the purpose and dispose by a licensed company.

7

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Keep grease nipples clean.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

8

All slide bearings must be depressurised for the grease to be able to penetrate.

9

While lubricating, check the functioning of the bearings and observe whether there is any bearing slackness.

10

The specified lubrication periods apply in favourable conditions and normal use. More frequent lubrication is recommended in more demanding conditions and in heavy use, particularly of the slide bearings.

11

Verify that the gear teeth of the open gear transmission are entirely lubricated.

Note: Do not use excessive lubricant. Excessive grease may cause bearing to overheat and reduces the lifetime of the bearings.

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

6.2.2 Lubrication Charts (Low headroom trolley)

Pos. H1 H2 H3 H4 H5 H6 K T1 T2

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Component Rope anchorage Hoisting gear Hoisting transmission Rope Rope drum bearings Rope guide Hook thrust/slide bearings Travelling gear Travelling transmission

Intervals Annual Lifetime lubricated Annual Monthly-Annual Annual Annual Annual if not life time lubricated Lifetime lubricated Annual

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

6.2.3 Lubrication Charts (Normal headroom trolley)

Pos. H1 H2 H3 H4 H5 H6 K T1 T2

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Component Rope anchorage Hoisting gear Hoisting transmission Rope Rope drum bearings Rope guide Hook thrust/slide bearings Travelling gear Travelling transmission

Intervals Annual Lifetime lubricated Annual Monthly-Annual Annual Annual Annual if not life time lubricated Lifetime lubricated Annual

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

6.2.4 Lubrication Charts (Double girder trolley)

Pos. H1 H2 H3 H4 H5 H6 K T1 T2

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Component Rope anchorage Hoisting gear Hoisting transmission Rope Rope drum bearings Rope guide Hook thrust/slide bearings Travelling gear Travelling transmission

Intervals Annual Lifetime lubricated Annual Monthly-Annual Annual Annual Annual if not life time lubricated Lifetime lubricated Annual

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

6.2.5 Lubrication Charts (Fixed hoist)

Pos. H1 H2 H3 H4 H5 H6 K

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Component Rope anchorage Hoisting gear Hoisting transmission Rope Rope drum bearings Rope guide Hook thrust/slide bearings

Intervals Annual Lifetime lubricated Annual Monthly-Annual Annual Annual Annual if not life time lubricated

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

6.2.6 Lubrication Charts (Machinery Hoist)

Pos. H1 H2 H3 H4 H5 H6

H1

Component Rope anchorage Hoisting gear Hoisting transmission Rope Rope drum bearings Rope guide

Intervals Annual Lifetime lubricated Annual Monthly-Annual Annual Annual

Rope anchorage • Lubricate the pivot joint of the lever mechanism, the suspension support of the rope anchorage and the rocker bushings of the support beam with suitable thin oil. Installation Factory installed Alternative Alternative Alternative

H2

Trade name and number Mobilith SHC460 Shell Gadus S5 V220 Neste Synlix Castrol S

Hoisting gear • Check magnetic plug for metallic particles. Check that breather is functional. If any abnormalities, contact service. Installation Factory installed Alternative Alternative Alternative Alternative Alternative

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Trade name and number Mobilux EP 004 Shell Alvania EP00 Shell Tivela Compound A Neste Center Grease 00 EP Castrol EPL 00 Mobilith SHC 007 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

H2

Hoisting gear • Check oil leakages, check oil level. If any abnormalities, contact service. Installation Factory installed Alternative Alternative

H3

Drum gear rim

Installation Factory installed Alternative Alternative

H3

Trade name and number Almagard 3752 Shell Gadus S3 High Speed Coupling Grease Neste Avora

Drum gear rim Installation Factory installed Alternative Alternative

H4

Trade name and number Mobil SHC 634 Neste Vaihteisto S 460 EP Shell Gear Oil HDS 460

Trade name and number Almagard 3752 Shell Gadus S3 High Speed Coupling Grease Neste Avora

Rope • • • •

To extend rope lifetime, lubrication is recommended. Lubrication interval varies from one month to one year depending on usage. Lubrication shall be done before signs of corrosion or dryness. Lubricate the rope with suitable lubrication. Lubricant for wire rope shall be water resistant, non-adhesive, transparent thin oil, which is able to penetrate into the rope. • Only lubricate the rope lightly, excessive lubrication may cause dribbling Installation Factory installed Alternative Alternative Alternative

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Trade name and number Elaskon 30 Lubriplate ORAPI Nanolubricant

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

H5

Rope drum bearings • Lubricate only the greasing points A (upper points) or B (lower points), but not both. • During lubrication, the drum MUST rotate at least two complete rounds. • Do not use excessive grease, as that may damage the bearings. Approximately two pumps of grease will suffice. Installation Factory installed Alternative Alternative Alternative

H6

Trade name and number Mobilith SHC460 Shell Gadus S5 V220 Neste Synlix Castrol S

Rope guide for hoist frame size SX1 • Lubricate the both intermediate shafts. Installation Factory installed Alternative Alternative Alternative

H6

Trade name and number Mobilith SHC460 Shell Gadus S5 V220 Neste Synlix Castrol S

Rope guide for hoist frame size SX2, SX3, SX4, SX5 • Lubricate the connector rod. Installation Factory installed Alternative Alternative Alternative

H6

Trade name and number Mobilith SHC460 Shell Gadus S5 V220 Neste Synlix Castrol S

Rope guide for hoist frame size SX6, SX7 • Lubricate the rotation support bearings locating at the both sides of the intermediate shaft. Installation Factory installed Alternative Alternative Alternative

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Trade name and number Mobilith SHC460 Shell Gadus S5 V220 Neste Synlix Castrol S

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

K

Hook thrust/slide bearings • Lubricate all lubrication points Installation Factory installed Alternative Alternative Alternative

T1

Trade name and number Mobilith SHC460 Shell Gadus S5 V220 Neste Synlix Castrol S

Traveling gear • Travelling machinery is grease lubricated and no oil changes are required. The breather plug can be used as a filling hole if it becomes necessary to top up the grease. Installation Factory installed Alternative Alternative Alternative Alternative Alternative Alternative

T2

Trade name and number Mobilux EP 004 Shell Gadus S1 Low Speed Coupling Grease Shell Gadus S2 V220 Shell Gadus S5 V142W Neste Center Grease 00 EP Castrol EPL 00 Mobilith SHC 007

Travelling transmission • Remove the plug and grease open transmission. Installation Factory installed Alternative Alternative

T2

Trade name and number Almagard 3752 Shell Gadus S3 High Speed Coupling Grease Neste Avora

Traveling wheel bearings • There are grease nipples on both sides of each wheel. Lubricate the grease nipples so that fresh grease penetrates all of the lubrication points. Installation Factory installed Alternative Alternative Alternative *) Synthetic

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Trade name and number Mobilith SHC460 *) Shell Gadus S5 V220 *) Neste Synlix *) Castrol S *)

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

6.2.7 Lubricant volumes, hoisting gears Drum size φ 243 mm φ 303 mm

Gear type GEN0 GEN1

Volume

φ 355 mm

GEN2

900 ml

31.7 fl.oz (Imperial)

φ 406 mm

GEN3

1400 ml

49.3 fl.oz (Imperial)

φ 608 mm

GEN4

2500 ml

88.0 fl.oz (Imperial)

300 ml 600 ml

10.6 fl.oz (Imperial) 21.1 fl.oz (Imperial)

6.2.8 Lubricant volumes, drum rim gear Drum diameter φ 243 mm

Volume

φ 303 mm

50 ml 70 ml

1.8 fl.oz (Imperial) 2.5 fl.oz (Imperial)

φ 355 mm

100 ml

3.5 fl.oz (Imperial)

φ 406 mm

150 ml

5.3 fl.oz (Imperial)

φ 608 mm

500 ml

17.6 fl.oz (Imperial)

6.2.9 Lubricant volumes, traveling gears Hoist trolley type Low headroom Normal headroom Double girder

Drum size all

Gear type GEK1

20 ml

0.7 fl.oz (Imperial)

φ 303 mm

DS2/DS3

400 ml

14.1 fl.oz (Imperial)

Double girder Double girder Double girder

φ 355/406/608 mm φ 608 mm φ 608 mm

GES3 GES4 GES5

250 ml 500 ml 1000 ml

8.8 fl.oz (Imperial) 17.6 fl.oz (Imperial) 35.2 fl.oz (Imperial)

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Volume

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

7

MAINTENANCE INSTRUCTIONS

7.1

Hoisting machinery

7.1.1 Hoisting machinery The hoisting machinery consists of the subassemblies: hoisting gearbox and hoisting motor. Details about hoisting gearbox and motor can be found in their respective sections. Hoisting machinery, Frame size: SX1, SX2, SX3, SX4, SX5.

1. Hoisting gearbox 2. Hoisting motor 3. Hoisting machinery 4. Rope drum assembly 5. Limit switch assembly

Disassembly WARNING

Lock the rope drum to prevent it from rotating when hoisting brake is detached. The weight of falling rope can rotate the unlocked drum and cause hazardous situation.

WARNING

The hoisting machinery is heavy. You need a lifting device when disassembling the hoisting machinery.

CAUTION

It is recommended to replace the coupling each time when you detach the hoisting motor from the gear. If you find any rust or other visible marks of wear in the coupling, you must replace the coupling with new one.

CAUTION

45/218

Be careful when removing the hoisting machinery not to damage the grease cover.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc. Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

1

2

Lower the hook to the ground. Switch OFF the power supply of the hoist. Remove the protective cover of the hoisting machinery. Lock the rope drum with, for example, a wooden wedge, in order to prevent it from rotating.

3

Remove hoisting limit switch assembly and cover (5). Remove the screw (7) so that the lifting device can be attached.

4

Install the lifting device (E) to the hoisting gearbox. Remove the mounting screws (A,B,C,D) and remove the hoisting machinery (3) from the drum end plate using the lifting device.

5

6

Remove the fan cover (9). Remove the screws in order to remove the hoisting motor (2) from the gearbox (1).

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Remove the bushing (6) around the brake cable. Detach the brake cable from the connector so that it can be removed easily while removing motor.

Remove the coupling (11) and remove the 3 screws in order to detach the grease cover (10).

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Reassembly

1

2

Grease the axle and inner surface of the coupling (11) thoroughly with a brush.

3

4

Grease the motor side coupling teeth after the coupling is installed. Install the grease cover (10) to the gearbox (1) with three screws.

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A coupling that has a groove outside MUST be installed with the groove facing the gear. Couplings in some gears of bigger size do not have any groove outside and they can be installed in both ways.

Lift the hoisting motor (2) above the gearbox. Pass the power cables and the brake cable through the holes in the hoisting gear

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

5

6

Ensure the motor shaft engages with the coupling and the screw holes align. Install the four mounting screws (A, B, C and D) and washers to the gearbox (1). Tighten them to the recommended torque (see “Appendix: tightening torques”). Reassemble the fan cover (9) with screws.

Tighten the bushing (6) on the brake cable. Insert the brake cable wires into the connector (A). Pin 13 (P13) = Brown wire Pin 14 (P14) = Blue wire

Note: When hoisting motor is placed check the installation by checking the hoisting motor and gear joint. The faces of joint must be completely attached to each other.

7

8

Install the hoisting machinery with the mounting screws (A, B, C,D) and grease the gear rim through the opening in the grease cover (E).

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Install the countersunk screw (7). Install the hoisting limit switch assembly (5) with the cover.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Hoisting machinery, Frame size: SX6, SX7.

1. Hoisting gearbox 2. Hoisting motor 3. Hoisting machinery 4. Junction box 5. Hoisting limit switch assembly

Disassembly

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WARNING

Lock the rope drum to prevent it from rotating when hoisting brake is detached. The weight of falling rope can rotate the unlocked drum and cause hazardous situation.

WARNING

The hoisting machinery is heavy. You need a lifting device when disassembling the hoisting machinery.

CAUTION

It is recommended to replace the coupling each time when you detach the hoisting motor from the gear. If you find any rust or other visible marks of wear in the coupling, you must replace the coupling with new one.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

1

2

If you must disassemble both the hoisting motor and the hoisting gearbox from the drum assembly, start by disassembling the junction box and the cabling inside the junction box (4). If you must disassemble the hoisting limit switch assembly (5), open first the switch cover and disassemble the wiring, before removing the whole limit switch assembly.

Remove fan cover (6). Remove the motor (2) by removing the screws holding it to the hoisting gear.

If you disassemble only the hoisting motor, it is possible to detach only the motor part and pull out some of the motor cabling, without disassembling the junction box.

3

4a

Attach the lifting device (A) and remove the mounting screws, the connecting plate (8), and shim plate (9). Remove also the two dowel pins (10) along with the connecting plate.

Remove the coupling (7) on the reducer gear shaft.

4b

5

Remove the mounting screws also from the left side of the gear.

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Remove the sleeve (11) from the hoisting gear axle, in case it remains there after removing the gearbox with a lifting device.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

R&M Materials Handling, Inc. Distributed by Tri-State Equipment Company Inc. Email: [email protected] Web: www.tsoverheadcrane.com PH: 314-869-7200 | FAX: 314-869-7226

Reassembly

1

Place the sleeve (11) at the base of the hoist axle. Apply silicone adhesive on the seal plate and end plate joint and on the sleeve.

2a

2b

Use the lifting device (A) to install the gearbox. Align the gearbox axle carefully on the gear rim (B).

Check the alignment of the holes and correct the alignment by using metal rods (C), if necessary

3a

3b

Place the connecting plate (8) with the help of the metal rods.

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Place the shim plate (9) under the connecting plate (8) and fasten the gear to its place by using the mounting screws. Fasten also the mounting screws to the left side (A) of the gear. Install the two dowel pins (10) top and bottom corners of the connecting plate.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

4

5

Install and grease the gear rim and coupling (7) thoroughly on the reducer gear shaft. A coupling that has a groove outside MUST be installed with the groove facing the gear. Couplings in some gears of bigger size do not have any groove outside and they can be installed in both ways.

6

7

Install the hoisting motor (2) with screws. Tighten the screws to the recommended torque. Reassemble the fan cover (6) and screws.

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Lift the hoisting motor (2) and align motor shaft with the coupling. Pass the motor power cables through the hole in the hoisting gear (1).

Connect the motor cabling and install the junction box (4). Install the hoisting limit switch assembly (5) and place the limit switch assembly cover box.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

7.1.2 Rope drum 7.1.2.1 Construction of rope drum for hoist frame size: SX1, SX2, SX3, SX4, SX5

1. Rope drum 2. Needle-bearing strip (bearing band) 3. Bearing housing 4. Sealing 5. Connector rods 6. Rim gear cover and inspection hole 7. Rim gear 8. Axial locking part A. Lubrication point for drum bearing B. Lubrication point for drum bearing

7.1.2.2 Construction of rope drum for hoist frame size: SX6, SX7

1.Rope drum 2.Bearing 3.Bearing frame 4.Sealing 5.Cover and inspection hole 6.Rim gear

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R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

7.1.2.3 Maintenance tasks for rope drum

1

2

Check the proper rotation of rope drum with and without load. Pay attention to running sound of rope drum bearings and check that the rope drum does not touch with machinery end plates.

3

Lower the hook to the ground and check the grooves of the drum. Healthy grooves are smooth and do not have sharp edges. If any doubt, unwind some more rope from the drum and compare the used grooves with unused grooves. Measure the groove wear if needed. Lubricate the drum surface.

4

Hoist frame size: SX1, SX2, SX3, SX4, SX5 Check the drum axial locking parts (8) for wear. If you notice any visible marks of wear (max. 2 mm), replace the axial locking part with new one. Lubricate groove in the drum, in which the axial locking part (8) is located.

Inspect visually and lubricate: • The gear rim through the inspection hole (6). Hoist frame size: SX1, SX2, SX3, SX4, SX5 • The drum bearing through the lubrication point (A) or (B) When lubricating the drum, it is recommended to mark the starting point in order to know when one rotation is complete.

CAUTION

Only lubricate the greasing points A OR B, but not both. During lubrication, the drum MUST rotate at least two complete rounds. Do not use excessive grease, as that may damage the bearings. Approximately two pumps of grease are sufficient.

CAUTION

Use only the spare parts that are provided by the original manufacturer(s).

7.1.2.4 Drum wear inspection The rope drum must be replaced if: The groove wear is more than allowed. A crest of the drum is bent towards groove. The wear of the teeth of the drum rim gear is visible. Drum frame size: SX1, SX2, SX3, SX4, SX5: the wear of the drum bearing running surface is more than allowed. Drum frame size: SX1, SX2, SX3, SX4, SX5: drum bearing housing has sharp edges that cannot be filed down, or is otherwise damaged. 54/218

Inspection method: Measurement, see the following figures and the table. See also “General Overhaul Instructions”. Visual. A sharpened crest is allowed if it is not bent towards the groove (the sharp area can be removed by filing if the crest wear dimension is still acceptable after filing). Visual. Teeth are broken or missing, or they have sharp endings or are otherwise clearly worn out. Measurement. See the figure and the table as follows. See also “General Overhaul Instructions”. Visual.

R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.

Measuring drum groove wear Clean the rope drum grooves before you start measuring groove wear.

1

2

Place the drum groove gauge on top of the grooves on the non-worn area of the rope drum. Measure the clearance between the groove and the drum groove gauge with a wire feeler gauge. Instead of a wire feeler gauge, you can also use a steel wire of same size.

Hoist frame size

SX2, SX3

SX4

Rope diameter

6.4 mm**

8.0 mm

[mm] 303

Nominal dimension Drum nominal diameter (D) Drum diameter at groove crest (d1)

Place the drum groove gauge on top of the grooves on the worn area of the rope drum. Measure the clearance between the groove and the drum groove gauge with a wire feeler gauge. Compare the measurement result with the result from the nonworn area, and see the acceptance criteria in the following diagram and table.

[mm]

SX5 11 mm (one rope) [mm]

SX5 8 mm (two ropes) [mm]

SX6 15 mm (one rope) [mm]

SX6 11 mm (two ropes) [mm]

SX7 15 mm (two ropes) [mm]

355

406

406

608

608

608

301.8

353

403.2

404

604.2

605.2

604.2

Drum diameter at groove bottom (d2)

297

347

395

398

593

597

593

Groove pitch (P)

7.2

9.1

12.5

9.1

17.1

12.5

17.1

Groove depth (H)

2.4

3.0

4.1

3.0

5.6

4.1

5.6

Groove radius (R) Acceptance criteria The difference between the worn area and non-worn area in groove depth and radius:

3.4

4.2

5.8

4.2

8.0

5.8

8.0

[mm]

[mm]

[mm]

[mm]

[mm]

[mm]

[mm]

1.0

1.0